Solenoid Valve Rounded Stop Surfaces Edge Loading
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Solution Overview
Problem
Solenoid valves in high-pressure fuel pumps face issues with wear and hydraulic sticking due to edge loading and misalignment during switching, which affect switching accuracy and longevity.
Innovation Solution
The magnet core and armature have rounded stop surfaces with a convex configuration, reducing edge loading and hydraulic sticking by eliminating misalignment and optimizing contact forces, with rounding dimensions between 30 μm to 500 μm, and optionally hardened for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the armature and magnet core have flat stop surfaces, then the structure is simple and easy to manufacture, but edge loading occurs during switching causing wear and reduced reliability
Solution Approach 1:
The patent applies curvature by rounding the stop surfaces of both the armature and magnet core. Instead of flat surfaces that cause edge loading, the rounded surfaces distribute contact forces across a broader area, eliminating edge loading effects and preventing hydraulic sticking. This curvature modification directly resolves the technical contradiction by improving reliability through reduced wear and sticking while maintaining manufacturing feasibility.
2Reliability
If the armature strikes the magnet core in a misaligned position during switching, then the structure remains simple, but edge loading causes wear and reduces service life
Solution Approach 1:
The rounded configuration of the stop surfaces accommodates misalignment during switching operations. When the armature strikes the magnet core in a misaligned position, the curved surfaces guide the contact to occur at the rounded edges rather than creating concentrated edge loading. This distributes the impact forces and prevents premature wear, extending service life without requiring complex alignment mechanisms.
3Productivity
If the armature detaches from the magnet core during switching, then the switching function is achieved, but hydraulic sticking occurs due to flat contact surfaces
Solution Approach 1:
The rounded stop surfaces prevent hydraulic sticking during armature detachment. The curvature creates a gradual separation path that allows fluid to escape from the contact interface as the armature moves away from the magnet core. This eliminates the vacuum effect that causes hydraulic sticking on flat surfaces, enabling rapid and clean switching without sticking delays.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances switching accuracy and significantly reduces wear, ensuring trouble-free operation of the solenoid valve over its service life in high-pressure fuel pumps and other applications.
Implementation Method 1
when voltage is applied to the magnetic coil, a magnetic force builds up, which attracts the armature against the spring force of the armature spring
Implementation Method 2
the armature is acted upon by an armature spring, which pushes the armature away from the magnetic core
Data Source
Figure 1
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Figure 4~5
AI summary
The invention relates to a solenoid valve having an actuator body (17), in which a magnet coil (15) that interacts with a magnet core (16) is arranged and which interacts with an armature (14) that can be moved relative to the magnet core between two end positions and is acted upon by the spring force of an armature spring (13) in a movement direction pointing away from the magnet core (16). The magnet core and the armature have stop surfaces (18a, 18b) which are interrupted by a recess (29) that receives the armature spring. According to the invention, a solenoid valve is provided which is improved with respect to the function of the solenoid valve and the stress on the stop surfaces (18a, 18b) that causes wear. This is achieved in that the magnet core (16) and/or the armature (14) have/has a design (30, 31), in particular a spherical or toroidal design, which reduces the stress on the edges in the region of the stop surfaces (18a, 18b).